3D die stacking structure with fine pitches

ABSTRACT

A package includes package includes a first package component including a first plurality of electrical connectors at a top surface of the first package component, and a second plurality of electrical connectors longer than the first plurality of electrical connectors at the top surface of the first package component. A first device die is over the first package component and bonded to the first plurality of electrical connectors. A second package component is overlying the first package component and the first device die. The second package component includes a third plurality of electrical connectors at a bottom surface of the second package component. The third plurality of electrical connectors is bonded to the second plurality of electrical connectors. A fourth plurality of electrical connectors is at a bottom surface of the second package. The second and the fourth plurality of electrical connectors comprise non-solder metallic materials.

PRIORITY CLAIM AND CROSS-REFERENCE

This application is a divisional of U.S. patent application Ser. No.14/074,186, entitled “3D Die Stacking Structure with Fine Pitches,”filed on Nov. 7, 2013, which application is incorporated herein byreference.

BACKGROUND

With the evolving of semiconductor technologies, semiconductorchips/dies are becoming increasingly smaller. In the meantime, morefunctions need to be integrated into the semiconductor dies.Accordingly, the semiconductor dies need to have increasingly greaternumbers of I/O connections packed into smaller areas, and the density ofthe I/O connections rises quickly over time. As a result, the packagingof the semiconductor dies becomes more difficult, which adverselyaffects the yield of the packaging.

The increase in the density of the I/O connections results in thereduction in the pitch of the IO connections. As a result, the closelylocated solder regions, which are used to form the IO connections in thebonding processes, are more likely to bridge with each other.

One of the methods for packaging integrated circuits is die stacking,which is also sometimes referred to as three-dimensional (3D) diestacking. 3D Die stacking structures have reduced footages than thepackages in which dies are disposed on the same plane. For example, in aconventional package, a first die is bonded to a second die through-flipchip bonding, wherein the second die has a larger area than the firstdie. The second die includes additional bond pads on the same side asthe first die, which additional bond pads are not used for bonding tothe first die. A third die is then bonded to the second die throughflip-chip bonding, wherein the third die is bonded to the additionalbond pads on the second die.

The third die has an area larger than the areas of both the first dieand the second die. The third die, in addition to the bond pads that areused to bond to the second die, also includes extra bond pads that areon the same side (of the third die) as the first die and the second die.The third die may then be bonded to a package substrate through theextra bond pads.

In the above-discussed package, the first die and the second die have afirst distance. The second die and the third die have a second distancegreater than the first distance. The third die and the package substratehave a third distance greater than the second distance. Accordingly, thesolder balls that are used to bond the third die to the second die arelarger than the solder balls that are used to bond the first die to thesecond die. The solder balls that are used to bond the package substrateto the third die are larger than the solder balls that are used to bondthe third die to the second die. The increase in the sizes of the solderballs causes the increase in the required size of the third die and thepackage substrate. In addition, the increase in the sizes of the solderballs also results in the increase in the pitches of the solder balls.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the embodiments, and the advantagesthereof, reference is now made to the following descriptions taken inconjunction with the accompanying drawings, in which:

FIGS. 1 through 8 are cross-sectional views of intermediate stages inthe manufacturing of a package in accordance with some exemplaryembodiments, wherein elongated metal bumps are used for bonding.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The making and using of the embodiments of the disclosure are discussedin detail below. It should be appreciated, however, that the embodimentsprovide many applicable concepts that can be embodied in a wide varietyof specific contexts. The specific embodiments discussed areillustrative, and do not limit the scope of the disclosure.

A package and the method of forming the same are provided in accordancewith various exemplary embodiments. The intermediate stages of formingthe package are illustrated. The variations of the embodiments arediscussed. Throughout the various views and illustrative embodiments,like reference numbers are used to designate like elements.

FIGS. 1 through 8 illustrate the cross-sectional views of intermediatestages in the manufacturing of a package in accordance with someembodiments. Referring to FIG. 1, package component 100 is formed. Insome embodiments, package component 100 is a device die, which includesactive devices (not shown) such as transistors therein. Passive devices(not shown) such as capacitors, resistors, inductors, transformers, andthe like, may also be built in package component 100. In alternativeembodiments, package component 100 may be a package that includes adevice and an interposer, a package substrate, or the like, wherein theinterposer and the package substrate include electrical connectionsinterconnecting the opposite sides, and may not include active devicestherein. Throughout the description, package component 100 is referredto as device die 100 hereinafter. In some exemplary embodiments, devicedie 100 is an Application Specific Integrated Circuit (ASIC) die, amemory die, a logic die, or the like.

On the top surface of device die 100 reside electrical connectors 102and 104. In some embodiments, electrical connectors 102 comprise metalpads, metal pillars (which may comprise copper, nickel, gold, orcomposite layers thereof), metal pillars with pre-solder layers, or thelike. Electrical connectors 102 and 104 are electrically connected tothe metal connections and active devices (not shown) in device die 100.Electrical connectors 104 have heights greater than that of electricalconnectors 102.

In some embodiments, electrical connectors 104 comprise stud bumps,which are formed by making wire bonding on the metal pads of device die100, and cutting the bond wire with a portion of bond wire left attachedto the respective bond ball. For example, in FIG. 1, electricalconnectors 104 may include lower portion 104A and upper portion 104B,wherein lower portion 104A may be a bond ball formed in the wirebonding, and the upper portion 104B may be the remaining bond wire.Upper portion 104B may have a uniform width and a uniform shape that areuniform throughout the top part, the middle part, and the bottom part ofupper portion 104B. In some embodiments, the ratio of the length L1 tothe width W1 of electrical connectors 104 is greater than about 1 andabout 10. For example, ration L1/W1 is greater than about 1, or greaterthan about 2. Hence, electrical connectors 104 may be elongatedconnectors. Electrical connectors 102 and 104 are formed of non-soldermetallic materials that do not melt at the normal temperatures (forexample, between about 220° C. and about 280° C.) that are used toreflow solder. In some exemplary embodiments, electrical connectors 104comprise copper, aluminum, nickel, gold, palladium, or the like, and mayhave a composite structure including a plurality of layers.

In alternative embodiments, electrical connectors 104 are formed throughelectrical plating. In which embodiments, a sacrificial layer (notshown) is formed over device die 100. A plurality of openings is formedin the sacrificial layer to expose the underlying metal pads (which mayform lower portions 104A) in device die 100. A plating step is thenperformed to plate electrical connectors 104. After the formation ofelectrical connectors 104, the sacrificial layer is then removed.

Referring to FIG. 2, package component 200 is bonded to device die 100through flip chip bonding. Package component 200 may be a device dieincluding active devices (not shown) therein. In some exemplaryembodiments, package component 200 is a power management die, a logicdie, a baseband die, or the like. Throughout the description, packagecomponent 200 is referred to device die 200. Device die 100 and devicedie 200 are bonded through solder regions 20, which are bonded betweenelectrical connectors 102 of device die 100 and electrical connectors202 of device die 200. Solder regions 20 may be solder balls that areattached to either or both of package components 100 and 200 before thebonding is performed. Throughout the description, each of solder regions20 in combination with the overlying electrical connector 202 and theunderlying electrical connector 102 is referred to as a bond structure.In some embodiments, electrical connectors 202 comprise metal pads,metal pillars (which may comprise copper, nickel, gold, or compositelayers thereof), metal pillars with pre-solder layers, or the like.

In some embodiments, the top ends 104C of electrical connectors 104 arehigher than the back surface 200A of die 200. In alternativeembodiments, the top ends 104C of electrical connectors 104 aresubstantially level with the back surface 200A of die 200. No electricalconnectors are formed on back surface 200A in some embodiments. Thelength of electrical connectors 104 may be equal to or greater than thecombined thickness of die 200, solder regions 20, and possiblyelectrical connectors 102.

Referring to FIG. 3, underfill 22 is dispensed into the gap betweendevice die 100 and device die 200 in order to protect the bonding ofdevice dies 100 and 200. Underfill 22 is then cured. In the resultingstructure, electrical connectors 104 may be aligned as a ring(s) (viewedfrom the top view of FIG. 3) encircling device die 100. Throughout thedescription, the structure in FIG. 3 is referred to as package 26.

FIG. 4 illustrates package component 300. In some embodiments, packagecomponent 300 is a device die, which includes active devices (not shown)such as transistors therein. Passive devices (not shown) such ascapacitors, resistors, transformers, and the like, may also be built inpackage component 300. In alternative embodiments, package component 300is an interposer, a package substrate, or the like, which do not includeactive devices therein. Throughout the description, package component300 is referred to as device die 300 hereinafter, although it may alsobe of other types. In some exemplary embodiments, device die 300 is alogic die, a baseband die, a memory die, or the like.

Electrical connectors 302 and 304 are formed at the top surface ofdevice die 300. In some embodiments, electrical connectors 302 comprisemetal pads, metal pillars (which may comprise copper, nickel, gold, orcomposite layers thereof), metal pillars with pre-solder layers, or thelike. Electrical connectors 302 and 304 are electrically connected tothe metal connections and active devices (not shown) in device die 300.Solder layers 306, which are sometimes referred to as pre-solder layers,are formed on electrical connectors 302.

Electrical connectors 304 are elongated connectors having heightsgreater than that of electrical connectors 302. Electrical connectors304 may be formed using essentially the same candidate methods that areused for forming electrical connectors 104. For example, electricalconnectors 304 may be stud bumps formed through wire bonding. Inalternative embodiments, electrical connectors 304 are formed throughelectrical plating. In some embodiments, the ratio of the length to thewidth of electrical connectors 304 is greater than about 4 and about 16.Electrical connectors 302 and 304 are also formed of non-solder metallicmaterials that do not melt at the normal temperatures (for example,between about 220° C. and about 280° C.) that are used to reflow solder.In some exemplary embodiments, electrical connectors 304 comprisecopper, aluminum, nickel, gold, palladium, or the like, and may have acomposite structure including a plurality of layers.

In some embodiments, back surface 300A of device die 300 does not haveany electrical connectors formed thereon. In alternative embodiments,device die 300 includes backside electrical connectors (such as metalpads, metal pillars, or solder layers) at back surface 300A, whichbackside electrical connectors are electrically connected to electricalconnectors 302 and/or 304.

FIG. 5 illustrates the bonding of package 26 to device die 300.Electrical connectors 104 are bonded to electrical connectors 302through solder regions 306. Hence, the circuits in devices 100 and 200are electrically connected to the circuits in device die 300. Throughoutthe description, each of solder regions 306 in combination with theoverlying electrical connector 104 and the underlying electricalconnector 302 is referred to as a bond structure. In some embodiments,surface 200A of device die 200 is in physical contact with the topsurface 300B of device die 300. In alternative embodiments, surface 200Aof device die 200 is spaced apart from surface 300B of device die 300.In these embodiments, device dies 100 and 200 may be suspended throughthe support of electrical connectors 304.

Referring to FIG. 6, underfill 28 is dispensed into the gap betweendevice die 100 and device die 300 in order to protect the bondingbetween device dies 100 and 300. Underfill 28 is then cured. In theembodiments in which surface 200A of device die 200 is spaced apart fromtop surface 300B of device die 300, underfill 28 may be filled into thegap between device dies 200 and 300. Alternatively, an air gap may beformed between device dies 200 and 300, which air gap is encircled byunderfill 28. Throughout the description, the package shown in FIG. 6 isreferred to as package 30.

FIG. 7 illustrates the bonding of the package 30 with package substrate400. Electrical connectors 304 are bonded to electrical connectors 402through solder regions 406, which may be pre-formed on package substrate400 before the bonding. Hence, the circuits in devices 100, 200, and 300are electrically connected to the metal traces 408 in package substrate400. Throughout the description, each of solder regions 406 incombination with the overlying electrical connector 304 and theunderlying electrical connector 402 is referred to as a bond structure.In some embodiments, surface 100A of device die 100 is in physicalcontact with the top surface 400A of package substrate 400. Inalternative embodiments, surface 100A of device die 100 is spaced apartfrom top surface 400A of package substrate 400. In these embodiments,device dies 100 and 200 may be suspended through the support ofelectrical connectors 304.

FIG. 8 illustrates the formation of solder balls 34 on package substrate400. Through the internal metal traces and vias 408 in package substrate400, solder balls 34 are electrically connected to electrical connectors304. Furthermore, molding compound 36 is dispensed into the gap betweenpackage 30 and package substrate 400, so that the bond structures thatbond package 30 to package substrate 400 are protected.

In some embodiments, pitch P1 of solder regions 204 is in the rangebetween about 25 μm and about 100 μm. It is appreciated, however, thatthe values recited throughout the description are merely examples, andmay be changed to different values. Pitch P2 of electrical connectors104 may be in the range between about 40 μm and about 100 μm. Pitch P3of electrical connectors 304 may be in the range between about 40 μm andabout 200 μm. In some embodiments, pitch P3 is equal to, smaller than,or greater than pitch P2. Furthermore, pitch P2 may be equal to orsmaller than pitch P1. In addition, there may exist the relationshipP3≤P2≤P1.

Since the distance D1 between dies 100 and 200 is small, using solderregion 20 to bond device dies 100 and 200 has an insignificant effect onthe pitch P1, and hence solder regions 20 are used to reduce themanufacturing cost. On the other hand, the distance D2 between dies 200and 300 and the distance D3 between die 300 and package substrate 400have high values (and are greater than distance D1). As a result, ifsolder balls are used for the respective interconnection, the pitches ofthe bond structures are large. Using the elongated connectors 104 and304 for the interconnection in the package thus has a significant effecton the reduction of pitches P2 and P3, respectively. Accordingly, in theembodiments of the present disclosure, a hybrid bond scheme is use inthe package, in which solder regions 20 is mixed with elongatednon-solder electrical connectors 104 and 304. The hybrid bond schemeresults in the reduction of the footage of the resulting package withoutexcessively increasing the manufacturing cost.

In accordance with some embodiments, a package includes a first packagecomponent including a first plurality of electrical connectors at a topsurface of the first package component, and a second plurality ofelectrical connectors longer than the first plurality of electricalconnectors at the top surface of the first package component. A firstdevice die is over the first package component and bonded to the firstplurality of electrical connectors, wherein the second plurality ofelectrical connectors has a length greater than a thickness of the firstdevice die. A second package component is overlying the first packagecomponent and the first device die. The second package componentincludes a third plurality of electrical connectors at a bottom surfaceof the second package component. The third plurality of electricalconnectors is bonded to the second plurality of electrical connectors. Afourth plurality of electrical connectors is at a bottom surface of thesecond package. The second and the fourth plurality of electricalconnectors comprise non-solder metallic materials. A third packagecomponent is underlying the first package component. The third packagecomponent is bonded to the fourth plurality of electrical connectors.The fourth plurality of electrical connectors has a length greater thana sum of the thickness of the first device die and a thickness of thefirst package component.

In accordance with other embodiments, a package includes a first devicedie, and a second device die over the first device die and bonded to thefirst device die through first bond structures. The first bondstructures have a first pitch. A third device die is overlying the firstdevice die and the second device die. The third device die is bonded tothe first device die through second bond structures, wherein the secondbond structures have a second pitch. A package substrate is under thefirst device die, wherein the package substrate is bonded to the thirddevice die through third bond structures. The third bond structures havea third pitch equal to or smaller than the second pitch.

In accordance with yet other embodiments, a method includes bonding adevice die to first electrical connectors of a first package component,wherein the first electrical connectors are at a top surface of thefirst package component. A second package component is bonded to secondelectrical connectors of the first package component, wherein top endsof the second electrical connectors are level with or higher than a topsurface of the device die. The second package component further includesthird electrical connectors at a bottom surface, with bottom ends of thethird electrical connectors level with or lower than a bottom surface ofthe first package component. The second electrical connectors and thethird electrical connectors are formed of non-solder materials. A fourthpackage component is to the bottom ends of the third electricalconnectors.

Although the embodiments and their advantages have been described indetail, it should be understood that various changes, substitutions andalterations can be made herein without departing from the spirit andscope of the embodiments as defined by the appended claims. Moreover,the scope of the present application is not intended to be limited tothe particular embodiments of the process, machine, manufacture, andcomposition of matter, means, methods and steps described in thespecification. As one of ordinary skill in the art will readilyappreciate from the disclosure, processes, machines, manufacture,compositions of matter, means, methods, or steps, presently existing orlater to be developed, that perform substantially the same function orachieve substantially the same result as the corresponding embodimentsdescribed herein may be utilized according to the disclosure.Accordingly, the appended claims are intended to include within theirscope such processes, machines, manufacture, compositions of matter,means, methods, or steps. In addition, each claim constitutes a separateembodiment, and the combination of various claims and embodiments arewithin the scope of the disclosure.

What is claimed is:
 1. A method comprising: forming a first plurality ofelectrical connectors on a top surface of a first package component,wherein the first package component further comprises a second pluralityof electrical connectors shorter than the first plurality of electricalconnectors, and the first plurality of electrical connectors is freefrom solder; bonding a second package component to the second pluralityof electrical connectors to form a first package, wherein the secondpackage component is over the first package component, and top surfacesof the first plurality of electrical connectors are substantially levelwith or higher than a top surface of the second package component;bonding the first package to a third package component to form a secondpackage, with the second package component being between the firstpackage component and the third package component, wherein the thirdpackage component is wider than the first package component, wherein thefirst plurality of electrical connectors is bonded to the third packagecomponent, and wherein the third package component further comprises athird plurality of electrical connectors formed of a non-soldermaterial; and bonding the second package to a fourth package componentto form a third package, with the third plurality of electricalconnectors being bonded to the fourth package component.
 2. The methodof claim 1, wherein the fourth package component is wider than the firstpackage component.
 3. The method of claim 1, wherein the third pluralityof electrical connectors is bonded to the fourth package componentthrough a second plurality of solder region.
 4. The method of claim 1further comprising: performing a wire bonding to form a bond ball on thetop surface of the first package component to form one of the firstplurality of electrical connectors; and cutting a wire connected to thebond ball to form the one of the first plurality of electricalconnectors, wherein a portion of the wire is left connected to the bondball to form the one of the first plurality of electrical connectors. 5.The method of claim 1 further comprising plating the first plurality ofelectrical connectors on the top surface of the first package component.6. The method of claim 1 further comprising forming the third pluralityof electrical connectors through wire bonding.
 7. The method of claim 1further comprising forming the third plurality of electrical connectorsthrough plating.
 8. The method of claim 1, wherein in the third package,the first package is between the third package component and the fourthpackage component.
 9. The method of claim 1, wherein the first pluralityof electrical connectors comprises a first electrical connector and asecond electrical connector separated by a space, and the second packagecomponent extends into the space.
 10. The method of claim 1, wherein thethird plurality of electrical connectors comprises a first stud bump anda second stud bump, and the first package component comprises a firstside edge and a second side edge opposite to each other, with both thefirst side edge and the second side edge being between the first studbump and the second stud bump.
 11. The method of claim 1, wherein thethird package component comprises a portion extending laterally beyond acorresponding left side edge and a right side edge of the first packagecomponent.
 12. The method of claim 1, wherein the second packagecomponent and the third package component are not electricallyinterconnected directly, and the second package component and the thirdpackage component are electrically intercoupled indirectly through thefirst package component.
 13. A method comprising: forming a firstplurality of electrical connectors on a top surface of a first packagecomponent, wherein the first package component further comprises asecond plurality of electrical connectors shorter than the firstplurality of electrical connectors, and the first plurality ofelectrical connectors is free from solder; bonding a second packagecomponent to the second plurality of electrical connectors to form afirst package, wherein the second package component is over the firstpackage component, and top surfaces of the first plurality of electricalconnectors are substantially level with or higher than a top surface ofthe second package component; bonding the first package to a thirdpackage component to form a second package, with the second packagecomponent being between the first package component and the thirdpackage component, wherein the third package component is wider than thefirst package component, wherein the first plurality of electricalconnectors is bonded to the third package component, and wherein thethird package component further comprises a third plurality ofelectrical connectors formed of a non-solder material, and wherein eachof the first and the third plurality of electrical connectors comprisesa stud bump comprising a bond ball and a bond wire connected to the bondball; and bonding the second package to a fourth package component toform a third package, with the third plurality of electrical connectorsbeing bonded to the fourth package component.
 14. The method of claim13, wherein the fourth package component is wider than the first packagecomponent, and the fourth package component extends beyond side edges ofthe first package component.
 15. The method of claim 14, wherein thethird package component is wider than the first package component. 16.The method of claim 13, wherein the second package component and thethird package component are not electrically interconnected directly,and the second package component and the third package component areelectrically intercoupled indirectly through the first packagecomponent.
 17. A method comprising: forming a first plurality ofelectrical connectors on a top surface of a first package component,wherein the first package component further comprises a second pluralityof electrical connectors shorter than the first plurality of electricalconnectors, and the first plurality of electrical connectors is freefrom solder; bonding a second package component to the second pluralityof electrical connectors to form a first package, wherein the secondpackage component is over the first package component, and top surfacesof the first plurality of electrical connectors are substantially levelwith or higher than a top surface of the second package component;bonding the first package to a third package component to form a secondpackage, with the second package component being between the firstpackage component and the third package component, wherein the thirdpackage component is wider than the first package component, wherein thefirst plurality of electrical connectors is bonded to the third packagecomponent, and wherein the third package component further comprises athird plurality of electrical connectors formed of a non-soldermaterial; and bonding the second package to a fourth package componentto form a third package, with the third plurality of electricalconnectors being bonded to the fourth package component, wherein thefirst package component is wider than the second package component, thethird package component is wider than the first package component, andthe fourth package component is wider than the third package component.18. The method of claim 17, wherein the second package component and thethird package component are not electrically interconnected directly,and the second package component and the third package component areelectrically intercoupled indirectly through the first packagecomponent.
 19. The method of claim 18, wherein the first packagecomponent and the fourth package component are not electricallyinterconnected directly, and the first package component and the fourthpackage component are electrically intercoupled indirectly through thethird package component.
 20. The method of claim 17, wherein the firstpackage component and the second package component are between the thirdpackage component and the fourth package component.